US3893194A

US3893194A - Simple relay structure

Info

Publication number: US3893194A
Application number: US446554A
Authority: US
Inventors: Rodney Hayden; Gordon M Davidson
Original assignee: TRW Inc
Current assignee: Northrop Grumman Space and Mission Systems Corp
Priority date: 1973-06-08
Filing date: 1974-02-27
Publication date: 1975-07-01
Anticipated expiration: 1992-07-01
Also published as: CA977014A

Abstract

A relay has a coil form part which includes a coil supporting tube and a flange at each end of the tube. The coil form part is formed as a one-piece plastic molding. A stationary core part includes a mounting flange and two, parallel, spaced apart core legs joined to the mounting flange. One of the core legs is inserted through the coil supporting tube of the coil form part. A movable armature structure is fastened to the other core leg, i.e., the leg which is not inserted within the coil supporting tube, in cantilever fashion, at the end of said other core leg remote from the mounting flange. The armature structure includes a movable core part supported thereby in spaced, overlapping relationship to the end of the core leg inserted through the coil supporting tube.

Description

United States Patent [1 1 Hayden et al.

llll 3,893,194

l l July 1,1975

[ SIMPLE RELAY STRUCTURE [75] Inventors: Rodney Hayden, Stoney Creek; Gordon M. Davidson, Grimsley. both of Canada [73] Assignee: TRW Inc., Cleveland, Ohio [22] Filed: Feb. 27, 1974 [2l] Appl. No.: 446,554

Related U.S. Application Data [63] Continuationin-part of Ser. No. 368,398, June 8. 1973, abandoned, which is a continuation of Ser. No. 277,843, Aug, 3. I972, abandoned.

[52] US. Cl. 335/202; 335/203; 335/297 [51] Int. Cl. HOlh 45/04 [58] Field of Search 335/202, 203, 187, 297, 335/196, 281, 282

[56] References Cited UNITED STATES PATENTS 3,372,356 3/1968 Hiyane et al 335/297 3,588,765 6/l97l Alten 335/203 3.723.925 3/l973 Alten 335/203 Primary Examiner-Harold Broome Attorney, Agent, or Firm-James R, O'Connor [57] ABSTRACT A relay has a coil form part which includes a coil supporting tube and a flange at each end of the tube. The coil form part is formed as a one-piece plastic molding. A stationary core part includes a mounting flange and two, parallel, spaced apart core legs joined to the mounting flange. One of the core legs is inserted through the coil supporting tube of the coil form part. A movable armature structure is fastened to the other core leg, i.e., the leg which is not inserted within the coil supporting tube, in cantilever fashion, at the end of said other core leg remote from the mounting flange. The armature structure includes a movable core part supported thereby in spaced, overlapping relationship to the end of the core leg inserted through the coil supporting tube.

22 Claims. ll Drawing Figures 1 SIMPLE RELAY STRUCTURE CROSS REFERENCE TO RELATED APPLICATION This application is a continuation in part of copending application Ser. No. 368,398 filed June 8, 1973, which application was a continuation of now abandoned application Ser. No. 277,843 filed Aug. 3, 1972.

BACKGROUND OF THE INVENTION 1. Field of the Invention The invention relates to direct current relay constructions of simple, sturdy form and arrangement which are particularly adapted for miniaturization and are particularly attractive for utilization in automotive applications.

2. Description of the Prior Art Due to the increasing requirement for relays in automobile electrical circuitry, the demand for sturdy relay structures adapted to operate reliably for more than one hundred thousand cycles of duty under conditions of vibration, temperature variation and humidity has developed an awareness of the structural weaknesses of conventional relay structures. A conventional relay structure will ordinarily comprise a coil wound upon a core, a core being riveted or bolted to a remainder core part and being fastened to an insulated base. Terminals are fastened to the base by metal rivets and metal contact structure rising from the base is usually fastened to the latter by rivets. It has been found that the assembly of relay structure and parts with an insulated base by metal riveting, press fitting, clamping or the like is apt to weaken rapidly due to vibration at a relatively early stage in service. The riveting together of metal core parts, such as the riveting or bolting of the coil core to the remainder core part likewise tends to loosen. Part of the difficulty arises from the forming of a rigid metal rivet connection between a metal part and a plastic part such as the insulated base. Changing thermal and humidity conditions cause minute changes in the dimensional characteristics of the plastic material about the rivet which in a short time develop a loose connection in many automobile relay structures. An automobile relay is required to be manufactured in large volume at very low cost. Thus the number of forming and assembling operations to be practiced in the manufacture of such relay must be a minimum and must be of simple nature.

It is a main object of the invention to provide a simple relay structure of a direct current type adapted for automotive use embodying a core structure adapted to conduct both magnetic flux and electrical current and comprising parallel spaced apart core legs joined at one end by a flange portion with the legs and flange portion being struck from the same sheet of metal, a movable core part extending between the other ends of the legs and spring means supporting the movable core part to define a magnetic gap for said core, said core part being adapted for rigid mounting on a supporting base by simple fastening means.

It is another object of the invention to provide a simple relay structure in which a small number of subassemblies may be connected in final assembly by fastening means which provide rigid, permanent connections.

Other objects of the invention will be appreciated by a study of the following specification taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWING FIG. 1 is a perspective view of one embodiment of a simple relay according to the invention;

FIG. 2 is a perspective view of the outer casing for the relay depicted in FIG. 1;

FIG. 3 is a perspective view of the coil form part of the relay;

FIG. 4 is an exploded view of the components of the relay except for the outer casing;

FIG. 5 is an exploded view of the armature components of the relay;

FIG. 6 is a perspective view of another form of a relay core part according to another embodiment of the invention;

FIG. 7 is a perspective view of a relay embodying the core part depicted in FIG. 6 and a coil form part especially adapted for miniaturization;

FIG. 8 is a perspective view of the coil form part of the relay depicted in FIG. 7;

FIG. 9 is a perspective view of a removable outer casing adapted for assembly with the base of the coil form part depicted in FIG. 8;

FIG. I0 is a top plan view of the relay structure of FIG. 7; and

FIG. 11 is a bottom plan view of the relay structure of FIG. 7.

DESCRIPTION OF A FIRST EMBODIMENT OF THE INVENTION In the drawings, the relay I0 of the invention generally comprises a coil form part II embodying an integral base part 12, a hollow spool or winding column 13 and upper winding flange 14. The base 12 lockably receives the outer casing 15 containing therewithin the winding 16 on spool 13 and armature assembly 17 fastened to core part 18 assembled with the coil form part 11 in a manner presentingg integrally formed external terminal members 19. Thus, on assembly, the base having the winding thereon has inserted therein the core part 18 to which is assembled the armature assembly 17 and including an additional relay contact end terminal assembly 20. These main components provided in the combination and form shown simplfy assembly operations and enable the application of reliable and simple techniques for fastening the components in assembled position.

In more detail the coil fomi part 11 is formed of a thermoplastic insulating material in which the base 12 is generally rectangular and generally features casing locking recesses 21 adapted to articulate with inwardly extending locking lugs 22 of the outer casing 15. Base 12 and flange l4 embody heat

deformable rivet posts

23, 24 and 25 being cast in situ of the same thermoplastic material as the coil form part. Base 12 also embodies suitably located

slots

26, 27. Coil form column 13 embodies a through bore 28 which is preferably rectangular in section.

The outer casing 15 in more detail comprises upstanding walls 29 rising from locking flange 30 at the lower outer terminus or open end 31 of the casing, the other end 32 being closed by a top wall 33. Side walls 34 carrying the indented or recessed wall portions 35 are adapted to be positioned relative to armature assembly 17 within the casing so as to transmit relay noise through contact part 36 located in touching relationship with the inner surfaces of a recessed portion 35 of a side wall 34. The casing is made of a flexurable thermoplastic material so that the locking flange 30 thereof may have its lugs 22 pressed over the base I2 for grip ping of lugs 22 in recesses 21 thus to retain the casing in firm assembly with the base 12.

The stationary core part 18 is struck from a sheet of ferrous material and includes a mounting flange 37 having two

rivet receiving openings

38,39 and at right angles to the mounting flange and a laterally folded winding core leg 40 spaced from a parallel, spaced apart, upstanding core leg 41, both of which core legs extend in one direction from the mounting flange 37. The two

terminal members

19 and 42 extend in the opposite direction at right angle to the mounting flange. The core legs. mounting flange, and terminals are struck from the same sheet of ferrous material to provide a single component for easy assembly of the

core legs

40,41 in the rectangular bore 28 and slot 26 of the coil form part II, respectively, such assembly being accomplished preferably after winding 16 has been wound on the exterior of the coil supporting tube 13 of the coil form part 11.

As is best seen in FIG. 5, the armature assembly 17 includes an electrical conductor strip 43 having a movable spring arm portion 44 struck therefrom and carrying at its free end 45 a contact bar 46. Movable core part 48, which is also formed from ferrous material. is spot welded to an intermediate portion 47 of the strip 43 at weld points 49 in such a manner that the other end 50 of the strip 43 may be spot welded at points 51 to the rigid upstanding core leg 41 after assembly of the latter with the coil form part 11. The movable core part 48 is of sufficient length to overlap surface 52 of the winding core leg 40, but is slightly spaced at its inner end 53 from the nearest edge 54 of the core leg 41 to provide a flexing portion 55 in the strip 43 of the relay armature.

The relay contact includes a contact supporting member 36 which has a contact bar 56 disposed thereon at right angles to mounting flange 57 having a rivet opening 58 adapated to seat over a rivet post within antitwist recess 59 of coil form part flange 14 to locate contact bar 56 at right angles to and in spaced relation to contact bar 46 of the relay armature l7. Terminal post 60 is formed of strip metal, as are all the other metal parts of the relay, and embodies a mounting flange 62 having a rivet receiving opening 63 adapted to seat on rivet post 23 of the coil form part. The terminal member 60 is adapted to pass through the rectangular opening 27 in the coil form part within the antitwist recess 64 which is adapted to restrict the terminal flange 62 against twisting. The terminal flange 62 carries a wire connecting post 65. The mounting flange 57 of relay contact 20 likewise carries a wire connecting post 66, said posts 65,66 being adapted for connection to the wire ends 67, 68 of the coil winding 16. The rivet posts 23,24,25 are deformed by heat to form plastic rivet heads and securely fasten the above described metallic relay parts to the coil form part.

As is evident from the foregoing description, the simple relay structure of the described embodiment of the invention provides an insulate coil form part including a base portion, a hollow coil supporting portion and a flange spaced from said base by said coil supporting portion, all formed from an insulating plastic material and having appropriate slots and associated rivet studs for assembly therewith of the metal relay parts. A magnetizable stationary core part is struck from sheet ferrous material to define spaced apart, rigid core legs, an intermediate supporting flange and at least one tenninal member extending from said flange in a direction opposite said core legs, the core legs being insertable through a slot in the base and into the core supporting portion of the coil form part. A stationary contact part and terminal part are mountable, respectively, on the flange and base of the coil form part. The stationary core part, the contact part and the terminal part each have rivet receiving holes for assembly with the rivet studs of the coil form part and are fastened thereto by heat forming heads on the rivet studs to provide rigid mechanical connections. The outer casing of the relay includes a side wall portion adapted to physically engage the stationary contact part of the relay for the transmission of sound. The core leg of the stationary core part which is not inserted in the coil supporting portion of the coil form part supports a movable armature assembly and movable core part forming a portion of said armature assembly.

DESCRIPTION OF A SECOND EMBODIMENT OF THE INVENTION The stationary core part 18 of FIG. 6 is a modified version of the core part 18 of FIG. 4 and represents an optimum form of core structure both for the conduction of magnetic flux and the conduction of direct electric current. Core part 18 of FIG. 6 is of such a proportionality in its organization of elements as to be particularly adapted for miniaturization to provide very small relays of high efficiency and high current switching capability, but of small physical volume as compared with core parts and relay structures heretofore used in automotive applications.

Thus, in FIG. 6, the core part 18 is revealed in a form in which the

upstanding legs

69 and 70 are each of the same width W, are separated by an opening of width W and extend integrally from a flange 7] of a minimum depth W. A tenninal bar 72 extends from an edge 73 of the flange 71 in a plane parallel to, but in a direction opposite to, the

legs

69,70 and opposite to the similarly dimensioned openings 74 between said legs. The core part 18 is struck from a single piece of sheet metal. The thickness of the metal is preferred, according to this embodiment of the invention, to be greater than WM and preferably not less than W/3, whereby in stamping opeations the thickness of the ferrous sheet metal strip to be stamped will, by virtue of the nature of the stamping operation, tend to determine the value of W for a preferred ratio of W/ 3 for the thickness of the metal being stamped. Preferably also, the height of each

leg

69,70 is on the order of 3W minimum to permit a coil of a height of at least 2W to be wound thereabout from the flange 71 upwards to leave a freestanding portion, for example, freestanding portion 75 on leg 69 having an armature mounting hole 76 to extend above the coil or winding region 77. The

legs

69,70 are in parallel, spaced apart relationship with respect to planes of their faces, but are transversely offset by a gap on the order of width G. The most remote (relative to each other) faces of said legs are displaced or offset by a distance equal to the width of the gap G plus the thickness t of the sheet material from which the core part is struck. The leg heights H preferably are sufficient to accommodate the height or thickness h of the base of the coil form part II shown in a modified form in FIGS. 7 and 8 through 11. The value of 11 preferably is on the order of W/2 minimum. The overall height of the coil form part 11 of FIG. 8 is on the order of Y plus it the coil or winding length L which can be accommodated is on the order of 2W between the

flanges

77 and 78 along the rectangular, tubular, coil support portion 79 which as a core leg receiving bore 80 extending therethrough and through the base part 81 and flange 78. The base part 81 has

openings

82, 83, 84 and 85 formed therethrough, and the upper flange 77 of the modified coil form part includes an upstanding tab 86 defining a stop which limits the movement of a modified form of armature structure 17 to be described hereinafter with reference to FIGS. 7 and 10.

Terminal leg 72 communicates electrically with the

legs

69,70 by way of an electrical path through the material of the core part 18 at any point in said core part of an electrical cross section at least equal to that of the core terminal leg 72 and, for this reason, the thickness of the flange 71 which serves as an electrical connection between

legs

69,70 and terminal leg 72 must be sufficient to afford this desired cross section of electrical pathway. Furthermore, the magnetic pathway between the

legs

69 and 70 through the flange 71 of the core part must not encounter any diminution of cross section for conducting magnetic flux. As is best depicted in FIG. 7, the core part 18 of FIG. 6 is inserted into the coil supporting tube of the modified coil form part 11 of FIG. 8 by inserting core leg 70 into the bore 80 from beneath the coil form part base 81 while simultaneously inserting core leg 69 through base opening 83 until the barbed protuberance 87 on leg 70 (see FIG. 6), which is in scraping engagement with the inner surface 88 of the coil support tube 79 defining bore 80, arrives at its final position in the bore as determined by full seating of the core part base 71 in the recess 89 of coil form part base 81 (see FIG. 11). Prior to the assembly of the core part 18 of FIG. 6 with the coil form part 11 of FIG. 8, a suitable relay winding 90 is wound on the coil support tube 79 of the coil form part 11. The core part 18 is then assembled with the coil form part 11 as described above. The terminal leg 91 extends through coil form part base opening 84 and rises thereabove and includes a locking flange 92 extending inwardly, i.e., toward the coil 90, and an upstanding stationary contct arm 93 joined to the flange 92 and suitably spaced laterally by a gap 94 from the core leg 70 as indicated in FIG. 10. The armature member 95 is preferably formed from a springy bronze material and is fastened by a rivet 96 to the free end 75 of core leg 69 and, optionally, an overlying current conducting brass strip 97 is riveted, soldered. or welded to the armature member 95 and is riveted, soldered or welded to an adjacent face 98 of the leg 69 as at 99 (see FIG. 7) to provide increased electrical conduction from leg 69 to armature 95. The movable core part 100 is riveted or otherwise fastened to the inner face 101 of armature 95 and is of the length 2W and overlies the adjacent surface 102 of the upper end of core leg 70. The movable core part 100 is spaced from the surface 102 by a distance approximately equal to the width of gap G, and the free end 103 of the armature carries a movable contact 104 adapted to articulate with a fixed contact 105 carried by the stationary contact arm 93.

Terminal members

106 and 107 are similar and rise from the coil form part base 81 for the connection thereto of the wires of the coil 90, whereas

terminals

72 and 91 as seen in FIG. 11 provide electrical connections to the movable contact 104 and stationary contact 105, respectively. In the form shown the relay structure is in the normally open condition at which stop member 86 limits the outward position of the springy bronze armature thus determining a satisfactory tolerance for the contact gap 108.

It has been found that the core structure of FIG. 6, which is both an electrical and magnetic flux conducting core structure, is of a proportionate efficiency with respect to both electrical and magnetic functions and striking the same from a thinner magnetic flux conducting metal strip and appropriately adjusting the value of W as suggested herein leads to a surprisingly small physical size of relay for the handling of relatively large currents in automotive circuitry. Thus, the dimensions of housing 109 as shown in FIG. 9, which encloses the structure of FIG. 7 are ideally on the order of a maximum height dimension D; of approximately one centimeter for a current switching capability on the order of 20 amperes at a 50% duty cycle. The dimensions D and D are each less than the value of D,,. Primarily, the last described core part 18 will be recognized as a direct current type of C core wherein the flange portion 71 extending between the

legs

69,70 is struck from the same sheet of metal stock as said legs. In the last described embodiment, the legs and flange are all preferably of the same width and thickness as compared with the folded form of leg 40 of the FIG. 5 embodiment, although the latter provides the same flux conducting section as the wider leg 41. Thus, the invention pro vides for a simplicity of organization of relay components with attendant electric current and magnetic flux conducting efficiency, enabling substantially proportional miniaturization according to size requirements while maintaining substantially optimum flux and electric current conducting efiiciency.

The core parts shown in FIGS. 4 and 6 may, if desired, be fastened to the bases of coil form parts 11 by the use of adhesive coated

surfaces

110, 111 and 112, as shown in FIG. 6. By way of example, an adhesive having high heat resistance and electrical insulating properties such as an elastomer resin neoprene based adhesive in solvent may be applied as at 100, 111 and 112, as well as to the undersurface region as at 113 of the base 81 of coil form part 11. If adhesive fastening were employed with the earlier described first embodiment, then the heat deformation of the

rivet studs

23, 24 and 25 of FIGS. 3 and 4 may be rendered unnecessary, the rivets then serving only as convenient locating devices for the metal parts to be fastened. Furthermore, the invention contemplates the use of an adhesive in the fastening of each of the

terminals

91, 107 and 108 through the base of the coil form part 11, while peripheral surfaces 114 of the base, as seen in FIG. 8, may likewise be coated with adhesive to effect a more permanent fastening of the casing 109 to the coil form part. The invention thus provides a simple relay structure adapted to be entirely hermetically sealed from the atmosphere in that neoprene based adhesives afford excellent adhesion and bond and enjoy an extended life even when under attack by acids, oils, gasoline and other substances which may tend to promote corrosion.

We claim:

1. A relay structure comprising: a coil form part, said coil form part including a coil supporting tube and a flange at each end of said tube, said tube and said flanges being formed as one piece of an insulating material', a stationary core part, said core part including a mounting flange and two, parallel, spaced apart core legs joined to and extending from said mounting flange, one of said core legs being inserted within said coil supporting tube; and a movable armature structure fastened in cantilever manner to the other of said core legs proximate the end thereof remote from said mounting flange, said armature structure including a movable core part supported thereby in overlapping, spaced relationship to the end of said one core leg remote from said mounting flange.

2. A relay structure comprising: a coil form part, said coil form part including a coil supporting tube, a flange joined to one end of said tube and a base joined to the other end of said tube, said tube. flange and base being formed of an insulating material; a core part mounted on said base, said core part including a mounting flange having at least one rivet receiving hole therein, a terminal part joined to said mounting flange and extending at right angles from said mounting flange, and two parallel, spaced apart core legs joined to and extending from said mounting flange in a direction opposite said terminal part, one of said core legs being inserted within said coil supporting tube; at least one other terminal member having a mounting flange and a rivet receiving hole in said flange; rivets disposed in the holes of said mounting flanges rigidly fastening each of said mounting flanges to said coil form part; and a movable armature structure fastened to the other of said core legs.

3. A relay structure according to claim 2 wherein said core part comprises a ferrous sheet metal stamping and said one of said core legs includes a folded thickness of said ferrous sheet.

4. A relay structure according to claim 2 wherein said coil form part includes a mounting flange receiving recess for restraining twist of a mounting flange riveted thereto.

5. A relay structure according to claim 2 wherein said coil form part includes a mounting flange receiving recess for restraining a flange mounted therein against twist and a slot associated with said recess for receiving and rigidly retaining a portion of a part associated with said mounting flange.

6. A relay structure according to claim 2 wherein said tube. flange and base of said coil form part are formed as one piece of a heat deformable insulating material.

7. A relay structure according to claim 6 wherein said rivets are formed integral with said coil form part.

8. A relay structure according to claim 2 wherein said base of said coil form part has a slot formed therein and said other of said core legs extends through said slot.

9. A relay structure according to claim 8 wherein said mounting flange of said core part is fixed against the surface of said coil form part remote from said coil supporting tube.

10. A relay structure comprising: a coil form part in the form of a coil supporting tube having a flange at one end and a base at the other end formed in one piece of a heat deformable insulating material, a core part in the form of a mounting flange joining at least one terminal part extending at right angles therefrom to parallel spaced apart core legs extending therefrom in an opposite direction, said mounting flange having at least one rivet hole therein, at least one other terminal member having a mounting flange and a rivet hole therein, a slot in said base positioned to accommodate one of said core legs through said base, the other of said legs being inserted within said coil supporting tube, a rivet for the hole of each of said mounting flanges, each rivet extending from and being formed of the material of said coil form part and rigidly fastening each said mounting flange to the coil form part, and a movable armature structure fastened to said one of said core legs.

11. A relay structure according to claim 10 wherein said core part comprises a ferrous sheet metal stamping and the other of said core legs comprises a folded thickness of said ferrous sheet.

12. A relay structure according to claim 10 including a mounting flange accommodating recess in said coil form part for restraining twist of a mounting flange riveted thereto.

13. A relay structure according to claim 10 including a mounting flange accommodating recess in said coil form part for restraining a flange mounted therein against twist and a slot associated with said recess for rigidly accommodating a portion of a part associated with said mounting flange.

14. A relay comprising: a stationary core structure in the form of a ferrous sheet metal stamping for conducting both magnetic flux and electric current, said core structure including two, parallel, spaced apart core legs of substantially equal cross sectional area separated by an opening of substantially the same width as said core legs, said core legs being connected at one end thereof by an integral flange extending therebetween, a movable core part physically connected to the other end of one of said legs and overlying the other end of the other of said legs, and spring means supporting said movable core part to provide a magnetic gap between said movable core part and said other leg.

15. A relay according to claim 14 wherein said stationary core legs are of substantially equal length and width.

16. A relay according to claim 14 wherein one of said core legs is folded longitudinally.

17. A relay according to claim 14 wherein said movable core part overlies an area of the other of said core legs equal to the square of the width of said other leg.

18. A relay according to claim 14 including an insulate base and means rigidly fastening said flange of said core structure to said insulate base.

19. A relay according to claim 14 including an insulate base and a plurality of terminal members, said flange and said terminal members being adhesively fastened to said base.

20. A relay according to claim 14 including an insulate base, a plurality of terminal members and insulate means fastening said flange of said core structure and said terminal members to said base, a relay casing rising from said base, and means adhesively joining said casing to said base to hermetically seal said core structure within said casing.

21. A relay according to claim 14 including an insulate base having a coil support rising therefrom, said coil support having a through axial bore, a slot in said insulate base in predetennined location relative to said coil support bore, said one of said legs being seated in said slot, said other leg of said core structure being seated in said bore in said coil support, and means disposed between opposed surfaces of said insulate base, said coil support and said stationary core structure fas- 10 having a width W and a length 4W rigidly connected at one end to the end of said first leg remote from said flange and extending therefrom across said opening and beyond the end of said second leg remote from said flange, and a movable core part having a thickness 2, a nominal width W and a nominal length 2W fixed to said armature proximate said first core leg and overlying the end of said second core leg remote from said flange in spaced relationship thereto.

Claims

1. A relay structure comprising: a coil form part, said coil form part including a coil supporting tube and a flange at each end of said tube, said tube and said flanges being formed as one piece of an insulating material; a stationary core part, said core part including a mounting flange and two, parallel, spaced apart core legs joined to and extending from said mounting flange, one of said core legs being inserted within said coil supporting tube; and a movable armature structure fastened in cantilever manner to the other of said core legs proximate the end thereof remote from said mounting flange, said armature structure including a movable core part supported thereby in overlapping, spaced relationship to the end of said one core leg remote from said mounting flange.

2. A relay structure comprising: a coil form part, said coil form part including a coil supporting tube, a flange joined to one end of said tube and a base joined to the other end of said tube, said tube, flange and base being formed of an insulating material; a core part mounted on said base, said core part including a mounting flange having at least one rivet receiving hole therein, a terminal part joined to said mounting flange and extending at right angles from said mounting flange, and two parallel, spaced apart core legs joined to and extending from said mounting flange in a direction opposite said terminal part, one of said core legs being inserted within said coil supporting tube; at least one other terminal member having a mounting flange and a rivet receiving hole in said flange; rivets disposed in the holes of said mounting flanges rigidly fastening each of said mounting flanges to said coil form part; and a movable armature structure fastened to the other of said core legs.

6. A relay structure according to claim 2 wherein said tube, flange and base of said coil form part are formed as one piece of a heat deformable insulating material.

21. A relay according to claim 14 including an insulate base having a coil support rising therefrom, said coil support having a through axial bore, a slot in said insulate base in predetermined location relative to said coil support bore, said one of said legs being seated in said slot, said other leg of said core structure being seated in said bore in said coil support, and means disposed between opposed surfaces of said insulate base, said coil support and said stationary core structure fastening said core structure to said base and said coil support.

22. A relay comprising a stationary core part formed from a ferrous sheet metal stamping of uniform thickness t, said core part including first and second parallel, spaced apart core legs and a core flange connected said legs, said legs being separated by an opening having a width W and extending integrally from said flange, each of said legs having a width W, a length greater than 3W and a thickness greater than W/4, a flexible armature member formed from springy sheet metal having a width W and a length 4W rigidly connected at one end to the end of said first leg remote from said flange and extending therefrom across said opening and beyond the end of said second leg remote from said flange, and a movable core part having a thickness t, a nominal width W and a nominal length 2W fixed to said armature proximate said first core leg and overlying the end of said second core leg remote from said flange in spaced relationship thereto.